Engineered wall system

ABSTRACT

There is provided an engineered wall system which comprises at least one monolithic precast concrete foundation wall panel having top, bottom and opposing side edges. Each of the panels comprises a plurality of integral ribs, evenly spaced along a length of the panel between the side edges. The ribs are vertically oriented and project inwardly when the panel is in position as part of a building wall and a first and second outermost rib form each of the opposing side edges. There is a plurality of sleeve apertures located in the top edges and axially aligned in the opposing side edges and ribs and alignment means on the first and second outermost ribs to align adjacent ones of the panels. Attachment means on the first and second outermost ribs to secure together the aligned adjacent panels is also provided, as well as installation support pads attachable to the panels.

FIELD OF THE INVENTION

[0001] This invention relates to a precast engineered wall system comprising monolithic precast concrete panels suitable for foundation walls and above ground applications, including commercial buildings.

BACKGROUND OF THE INVENTION

[0002] The construction of foundations for residential and commercial building is a time and labour intensive process. It is often subject to the prevailing weather and often accounts for a significant portion of the delay in building projects.

[0003] Tilt slab construction, on site at building locations, has been used in recent years to attempt to circumvent some of the problems involved in the construction of building walls, both residential and commercial. However, tilt slab construction has been shown to have certain limitations, most notably the cost of material involved, since the slab will be solid concrete with steel reinforcing throughout.

[0004] There is thus a need to devise a system of constructing walls, including foundation walls, which eliminates some of the limitations of traditional construction techniques and which reduces the cost involved in tilt slab construction.

[0005] In that regard, there have been attempts made to develop a system of manufacturing walls using discreet wall panel sections. Many of those systems involve a precast wall panel to be manufactured on site or off and then installed together at the work site to form the foundation walls, as well as the other walls of the building. Theses systems have met with very limited commercial success, however, due to a variety of technical deficiencies. In particular, many of the existing panel systems require that the floor be poured before the foundation can be backfilled. If this is not done, the wall will not be adequately supported. This is contrary to normal building practice, however, in which the pouring of the floor is typically one of the last steps to be done. It is crucial, in the commercial success of any building product, but in particular a product for foundation walls, that the normal building sequence be disturbed as little as possible. Builders, most notably large builders working on tract housing, sub-divisions or the like will typically not accept a product or step which upsets their normal routine.

[0006] The existing systems have also failed commercially because of the increased cost associated with the system. Builders may accept a more expensive system if the cost can be passed on to the ultimate buyer. That buyer, however, is generally not prepared to accept a higher price for a house where the increase is associated with something unseen like the construction of a foundation. It is the applicant's experience that buyers are prepared to pay extra for features such as hardwood floors or bay windows but not for a foundation.

[0007] Thus, foundation wall systems which require expensive bolts or connectors and insulation as an integral part of the system, for example, increase the cost of the foundation to a point that render the systems commercially unacceptable.

[0008] The applicant is presently aware of the following patents and applications describing systems which suffer from many of these deficiencies:

[0009] Canadian Patent application 2,107,070 of Mion, “Panel System for Construction of Building Foundations”;

[0010] Canadian Patent 1,272,929 granted to Superior Walls of America Ltd., “Prefabricated Concrete Wall Structure”;

[0011] Canadian Patent 1,238,201 also granted to Superior Walls of America Ltd., “Sprayed Concrete Basement Structure”;

[0012] U.S. Pat. No. 4,605,529 also of Zimmerman, “Method of Constructing a Prefabricated Concrete Wall Structure”;

[0013] U.S. Pat. No. 4,934,121 of Zimmerman, “Integrated Reinforced Concrete Wall Structure”; and

[0014] U.S. Pat. No. 5,055,252 also of Zimmerman, “Method of Constructing an Integrated Concrete Wall Structure”.

[0015] Other references of background interest to the present invention include: Canadian Applications 2,169,527; 2,169,572; 2,191,491; 2,191,514; 2,297,515; 2,240,098; 2,274,287; and Canadian patent 1,167,272.

SUMMARY OF THE INVENTION

[0016] It is thus an object of the present invention to provide an engineered wall system which uses discreet precast panels which do not include the structural limitations that result in the commercial deficiencies of previous systems discussed above.

[0017] In one aspect of the invention, there is provided an engineered wall system which comprises at least one monolithic precast concrete wall panel having top, bottom and opposing side edges. Each of the panels comprises a plurality of integral ribs, evenly spaced along a length of the panel between the side edges. The ribs are vertically oriented and project inwardly when the panel is in position as part of a building wall and a first and second outermost rib form each of the opposing side edges. There is a plurality of sleeve apertures located in the top edges and axially aligned in the opposing side edges and ribs and alignment means on the first and second outermost ribs to align adjacent ones of the panels. Attachment means on the first and second outermost ribs to secure together the aligned adjacent panels is also provided, as well as installation support pads attachable to the panels.

[0018] In another aspect of the invention, the top, bottom and side edges are bevelled.

[0019] In another aspect of the invention, the top, bottom and side edges and an outermost face of the ribs further comprise steel studs fixed thereto.

[0020] In another aspect of the invention, there is a series of footings cast in place below the panels and between the pads, when the panels are in place to form a foundation wall.

[0021] In another aspect of the invention, the alignment means comprises a tongue and groove configuration on an outer surface of the side edges, from top to bottom of the side edges, constructed such that the tongue and groove configuration of one side edge of one panel cooperatively mates with the tongue and groove configuration of one side edge of an adjacent panel.

[0022] In another aspect of the invention, there is provided a method of constructing a foundation wall comprising the steps of:

[0023] clearing and leveling an area of ground on which the foundation is to be supported;

[0024] affixing at least two installation support pads to a plurality of monolithic precast concrete foundation wall panels;

[0025] placing the panels in position on the cleared and leveled area to form the foundation wall;

[0026] aligning adjacent of the panels and affixing all of the adjacent panels together;

[0027] leveling the installation pads;

[0028] pouring a concrete footing between the installation pads; and

[0029] backfilling around the foundation wall, so that the foundation wall is then ready to accept service cables, wires, plumbing therethrough, insulation, a top plate to support a floor thereabove and so that a concrete floor can then be poured around a bottom of the foundation wall.

BRIEF DESCRIPTION OF THE DRAWINGS

[0030] These and other advantages of the invention will become apparent upon reading the following detailed description and upon referring to the drawings in which:

[0031]FIG. 1 is a perspective view of a portion of an engineered wall system manufactured with the panels of the present invention.

[0032]FIG. 2 is a front elevation view of the panel of the present invention.

[0033]FIG. 3 is a cross-sectional view taken along line 3-3 of FIG. 2.

[0034]FIG. 4 is a plan view of a corner detail of the engineered foundation wall system.

[0035]FIG. 5 is a plan view of a detail of a rib of the panel of the present invention.

[0036]FIG. 6 is a sectional view taken along line 6-6 of FIG. 2.

[0037]FIG. 7 is an exploded sectional view of the top and bottom detail of the panel.

[0038]FIG. 8 is detail view of a foundation installation section.

[0039]FIGS. 9 a to 9 c are each a detail view of the footing for the panel.

[0040]FIGS. 10a to 10 d are each a detail view of an alternate embodiment of the invention.

[0041] While the invention will be described in conjunction with illustrated embodiments, it will be understood that it is not intended to limit the invention to such embodiments. On the contrary, it is intended to cover all alternatives, modifications and equivalents as may be included within the spirit and scope of the invention as defined by the appended claims.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0042] In the following description, similar features in the drawings have been given similar reference numerals.

[0043] Turning to the drawings, FIG. 1 illustrates a perspective view of a corner portion of a building wall 2, (shown for illustrative purposes as a foundation wall) constructed with precast panels 10 of the present invention. FIG. 2 is a front elevation view of the panel 10. The panel 10 has top 12, bottom 14, and opposing side 16 and 18 edges. The panel 10 is further characterized by a plurality of integral ribs 20 running vertically between the top 12 and bottom 14 edges. When the panel 10 is in position within a building wall 2, those ribs 20 project inwardly, as seen in FIG. 1. For any given panel the outermost ribs 22 and 24 form the side edges 16 and 18 respectively of the panel 10.

[0044] The panel is preferably cast of concrete in a single pour. Embedded within the concrete may be a welded wire mesh 26 in order to add strength and rigidity to the concrete, without an appreciable increase in mass, or cost of manufacture.

[0045] The panel 10 will also include a series of apertures, preferably in the form of sleeves 30 in the top edge 12 and sleeves 32 in the ribs 20, 22 and 24. Additional sleeves 34 may be included in the outermost ribs 22, 24. Those additional sleeves may function as part of the attachment means for attaching adjacent panels 10.

[0046] With reference to FIG. 3, the joining of two adjacent panels 10 and 10′ is illustrated (the designation ‘will be used to denote the common features between the two adjacent panels). The panels are arranged so that the first outermost rib 22 of one panel 10 mates with the second outermost rib 24 of the adjacent panel 10′. The sleeves 34 and 34′ would align to create a though hole between the adjacent panels. A bolt 36, or other suitable anchor may be used to fix the two panels together.

[0047] The ribs 20 will preferably include reenforcing metal bars 38 through the concrete. Similar reinforcing bars 39 will be in the top 12 and bottom 14 edges of the panel 10.

[0048] The outermost ribs 22, 24 will include an alignment system in order to accurately align the adjacent panels 10 and 10′. Preferably that alignment system will comprise a double tongue 40 and groove 42 configuration. The rib 22 will typically include the grooves 42 in an outermost surface of the rib 22, while the rib 24 will include the mating tongues 40 on an outermost surface thereof. That arrangement can be reversed without an adverse effect on its functionality.

[0049] In a preferred embodiment, the tongues 40 will be longer than the depth of the grooves 42. In this way a gap 44 will be left between adjacent panels. That gap can then be filled with caulking, gasketing or other waterproofing material. An exterior waterproofing membrane 46 will be applied over the joint of the two panels 10, 10′ to further seal the joint.

[0050] A corner detail is shown in FIG. 4, wherein a panel 10 is mating to an adjacent panel 10′ at a corner of the wall. In that configuration, only one of the tongues 40 will mate with a groove 42. A bolt 48 is still used to join the panels, but an additional anchor bolt 50 will preferably be used to secure that bolt 48 to the panel 10′, as illustrated.

[0051] FIGS. 5 to 7 show detail views of a preferred embodiment of the construction of the panel 10 of the present invention. In that preferred embodiment, the panel 10 includes steel studs on the ribs 20, top 12 and bottom 14 edges. In FIG. 5, the steel stud 60 is shown on the top edge 12 and would preferably be of 26 gauge steel. The studs 62, 64 is shown along the side of the rib 20 and would similarly be preferably of 26 gauge steel. A similar steel stud 66 would be included on the bottom edge 14.

[0052] As seen in FIG. 6, the steel studs 62, 64 are joined and covered by a covering layer, depicted as a sheet of asphenite 68. Similarly, a sheet of ashpenite 70 would join and cover the top and bottom studs 60, 66. The covering could alternately be formed of plywood or drywall, or any other suitably rigid material which could be used to join the studs and which would provide some thermal bridge between the studs as well. With the coverings 68, 70 in place on the panel, there would be no concrete or steel visible to a person viewing the panel 10.

[0053] The manner in which the panel 10 is installed on the ground in a typical foundation wall installation is depicted in FIGS. 8 and 9a to 9 c. The skilled person in the art will appreciate that there will be minor differences in the installation of the panels as part of an above-ground commercial wall. Those differences will, however, be largely determined by the building requirements and the nature of the differences inherent in building above-ground walls, as compared to foundation walls. The method of installing and particularly joining and sealing the panels will be essentially the same as that to be described.

[0054] The panel 10 rests on a plurality of precast installation pads 80. That pad 80 is of a width of preferably about 32 inches and houses an anchor bolt 82 in order to affix the panel 10 to the pads 80. It is contemplated that there will be approximately 2 pads 80 for each standard 16 to 20 foot wall section, although more pads can be used for longer sections. The panel 10 will typically be affixed to the pads 80 off site, but in any event, before installation of the panels 10 on site.

[0055] Once the panels have been installed and leveled, a concrete footing 84 can be poured, on site, between the pads 80. This footing 84, in combination with the pads 80, allow backfill 86 to be poured before the conventional floor 88 has to be poured. This represents a significant commercial improvement over many of the prior art systems known to the applicant. Once that is complete the wall is ready to accept a top plate 90 and a finished floor 92 in the conventional manner.

[0056] In operation, therefore, the panels 10 would be precast and a series of panels would be brought on site to complete the wall 2. Some of those panels 10 will include beam pockets 94 and window cutouts 96 (as shown in FIG. 1) in order to accommodate different foundation wall designs. The skilled person in the art will appreciate that other cutouts and modifications can be made to the panels 10 to accommodate design requirements.

[0057] The panels 10, attached to the pads 80 will be brought to building site. The area for the foundation wall will be cleared and leveled and a panel 10 will be placed on the area and leveled. An adjacent panel 10′ will then be aligned with panel 10 and the two will be attached, with the gaps filled as required. This will be repeated until the wall 2 is complete, with leveling throughout as required. Once the wall 2 is level, the footing 84 can be poured in place in between the pads 80 and the area can be backfilled. If necessary, a form can be inserted into the pads 80 to guide the pour of the footing 84. Once complete, work on the building can then continue in the normal fashion.

[0058] In an alternate embodiment of the invention, the steel studs are replaced on the top and bottom edges and the ribs by bevelled edges as shown in FIGS. 10a to 10 d. As seen in FIG. 10a, adjacent panels 100, 100′ are joined by the through bolt 160, preferably locked with a nut and bevelled washer. The ribs 122, 124 are each bevelled at 104, 106 respectively. A gap can be introduced between the adjoining panels by means of a spacer, such as plywood shims 108 as shown, or a thermal spacer such as a gasket or the like. Caulking, gasketting or other waterproofing material can also be used to fill the gap, and the joint is then covered with an exterior waterproofing membrane 146.

[0059] As seen in FIG. 10b, each rib 120 in this embodiment of the invention is bevelled on either side, as depicted at 150, 152. This double beveling has been found to be advantageous, particularly in the forming of the panels as it allows easy separation between the panel and the forming mould (not shown). Single beveling, on either side of the rib 120, as with the outermost ribs 122, 124 is also contemplated as an option for this embodiment.

[0060]FIG. 10c illustrates the corner detail in which an anchor bolt 162 is used to adjoin the panel 100, by its outermost rib 124, with the adjacent corner panel 101, with its bevelled top edge 112.

[0061]FIG. 10d illustrates the beveling on the top 112 and bottom 114 edges, as depicted at 164, 166 respectively. There remains a sleeve 130 in the top edge 112, as with the other embodiment. Optional loop lifting inserts 170 can be used to lift the panel 100 into position, such as at the work site.

[0062] It will be appreciated that the amount of reinforcing metal bars and overall dimensions of the panels will vary given the lateral and vertical load requirements of the building to be constructed, without departing from the overall structure of the panels.

[0063] Thus, it is apparent that there has been provided in accordance with the invention an engineered wall system that fully satisfies the objects, aims and advantages set forth above. While the invention has been described in conjunction with illustrated embodiments thereof, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art in light of the foregoing description. Accordingly, it is intended to embrace all such alternatives, modifications and variations as fall within the spirit and broad scope of the invention. 

I claim:
 1. An engineered wall system comprising: at least one monolithic precast concrete wall panel having top, bottom and opposing side edges, each of said panels comprising a plurality of integral ribs, evenly spaced along a length of said panel between said side edges, said ribs being vertically oriented and projected inwardly when said panel is in position as part of a building wall, a first and second outermost rib forming each of said opposing side edges; a plurality of sleeve apertures located in said top edges and axially aligned in said opposing side edges and said ribs; alignment means on said first and second outermost ribs to align adjacent ones of said panels; attachment means on said first and second outermost ribs to secure together said aligned adjacent panels; and installation support pads attachable to said panels.
 2. The system of claim 1 further comprising a reinforcing wire mesh within said concrete.
 3. The system of claim 1 further comprising metal reinforcing bars within said ribs.
 4. The system of claim 1 wherein said top, bottom and side edges are bevelled.
 5. The system of claim 1 wherein an outermost surface of said ribs is bevelled.
 6. The system of claim 1 wherein said top, bottom and side edges and an outermost face of said ribs further comprise steel studs fixed thereto.
 7. The system of claim 6 further comprising a joining layer to join adjacent steel studs on said ribs, so as to form a skin on said outermost face of said rib and a joining layer between said steel studs on said top and bottom edges.
 8. The system of claim 7 wherein said joining layer is constructed of a material selected from the group consisting of asphenite, drywall and plywood.
 9. The system of claim 1 further comprising wood strips affixed to said top, bottom and side edges.
 10. The system of claim 1 wherein said alignment means comprises a tongue and groove configuration on an outer surface of said side edges, from top to bottom of said side edges, constructed such that the tongue and groove configuration of one side edge of one panel cooperatively mates with the tongue and groove configuration of one side edge of an adjacent panel.
 11. The system of claim 1 wherein said attachment means comprises a through bolt passing through mating sleeves on said adjacent panels.
 12. The system of claim 1 wherein said sleeve apertures are configured on two foot centers.
 13. The system of claim 1 further comprising a series of footings cast in place below said panels and between said pads, when said panels are in place to form a foundation wall.
 14. The system of claim 13 further comprising an anchor bolt in said installation pads to secure said panel to said pads.
 15. The system of claim 1 comprising two pads per panel when said panels are in place to form a foundation wall.
 16. The panel of claim 1 further comprising an exterior veneer chosen from the group consisting of buffed finish, imprinted design or exposed aggregate.
 17. The system of claim 1 further comprising insulation and waterproofing means on exterior and interior surfaces at locations where said adjacent panels are joined together.
 18. The system of claim 1 wherein said panels may be provided with cutouts for support beams or windows.
 19. A method of constructing a foundation wall comprising the steps of: clearing and leveling an area of ground on which the foundation is to be supported; affixing at least two installation support pads to a plurality of monolithic precast concrete foundation wall panels; placing said panels in position on said cleared and leveled area to form the foundation wall; aligning adjacent of said panels and affixing all of said adjacent panels together; leveling said installation pads; pouring a concrete footing between said installation pads; and backfilling around the foundation wall, so that the foundation wall is then ready to accept service cables, wires, plumbing therethrough, insulation, a top plate to support a floor thereabove and so that a concrete floor can then be poured around a bottom of the foundation wall.
 20. The method of claim 19 further comprising the step of placing a form between said installation pads for said concrete pour.
 21. The method of claim 19 wherein each of said panels includes a plurality of integral ribs, evenly spaced along a length of said panel between said side edges, said ribs being vertically oriented and projected inwardlywhen said panel is in position as part of a foundation wall, to accept insulation therebetween, after said wall has been formed.
 22. The method of claim 19 wherein said individual of said panels may include a beam pocket or a window cutout.
 23. An engineered wall system comprising: at least one monolithic precast concrete wall panel having top, bottom and opposing side edges, each of said panels comprising a plurality of integral ribs, evenly spaced along a length of said panel between said side edges, said ribs being vertically oriented and projected inwardly when said panel is in position as part of a building wall, a first and second outermost rib forming each of said opposing side edges, said top, bottom and side edges and an outermost face of said ribs further comprising steel studs fixed thereto; a joining layer to join adjacent steel studs on said ribs, so as to form a skin on said outermost face of said rib and a joining layer between said steel studs on said top and bottom edges. a plurality of sleeve apertures located in said top edges and axially aligned in said opposing side edges and said ribs; alignment means on said first and second outermost ribs to align adjacent ones of said panels, said alignment means comprising a tongue and groove configuration on an outer surface of said side edges, from top to bottom of said side edges, constructed such that the tongue and groove configuration of one side edge of one panel cooperatively mates with the tongue and groove configuration of one side edge of an adjacent panel; attachment means on said first and second outermost ribs to secure together said aligned adjacent panels; at least two installation support pads per panel and attachable to said panels by means of an anchor bolt within each of said pads to secure said pads to said panel; a series of footings cast in place below said panels and between said pads, when said panels are in place to form the wall. 